top of page

3-Phase Squirrel-Cage Induction Motor

Results at a glance

enrique-mercader-icon-high-voltage.webp

Successful sustained operation with no load

208V 3-Phase

enrique-mercader-ac-motor-clipart-laminations.webp

Fabricated with commercial transformer laminations

Made from scratch

enrique-mercader-clipart-coils.webp

350 turns of #20 AWG enameled wire

Hand-Wound Coils

enrique-mercader-clipart-wye-delta.webp

Made with digital circuits and relays

Wye-Delta Starter

Overview

The 3-Phase Squirrel-Cage Induction Motor was a fully student-driven project completed during my Electrical Machines course. The sole objective was to design and build a functional 3-phase AC induction motor capable of running on a 3-phase 48 V AC source. With complete freedom in design and construction, our team chose to create a visually striking educational demonstrator featuring transparent acrylic panels that allow a clear view of the rotor spinning inside the motor during operation.


We designed and built every component from scratch: a custom stator core assembled from precisely cut and varnished transformer steel laminations, hand-wound coils using enameled magnet wire on a custom 3D-printed winding jig, and a squirrel-cage rotor with a modified core and 3D-printed conductive bar adapter. A Wye-Delta starter circuit using digital logic and relays ensured safe startup and smooth operation. The motor achieved reliable sustained no-load running, showcasing the rotating magnetic field in real time through the transparent enclosure.


Developed in equal collaboration with three fellow mechatronics engineering students, this project stands as a tangible demonstration of electromagnetic design, precision fabrication, and hands-on power electronics implementation.

Development Process

1

3D Modeling & Planning

Designed the complete motor in 3D to determine exact dimensions, material quantities, and manufacturing feasibility.

6

Hand-Wound Coils

Wound all stator coils by hand using a custom 3D-printed winding jig for perfect turns and tension.

11

Stator Completion

Final assembly of the stator with all coils secured and wiring routed.

16

Magnet Wire Current Testing

Stress-tested the magnet wire by passing 10 A DC through it to determine its real-world current limit for 208 V operation.

2

Cutting Transformer Laminations

Precisely cut transformer steel sheets into the custom stator and rotor shapes using the 3D model as reference.

7

Stator Core & Coil Integration

Inserted and secured the hand-wound coils into the assembled stator core.

12

Magnetic Field Validation

Tested the stator’s rotating magnetic field using a free-moving magnet to confirm proper three-phase operation.

18

First Successful Run

Powered up the finished motor and captured it running smoothly under full three-phase operation.

3

Varnish Application

Applied insulating varnish to every individual lamination to prevent eddy currents.

8

Coil Terminal Wiring

Routed and terminated all coil leads for proper three-phase Wye configuration.

13

Rotor Preparation

Recycled and modified an existing rotor, then designed and 3D-printed an iron-filled PLA adapter to mount the squirrel cage bars.

4

Lamination Organization

Applying varnish to each of the laminations

9

Continuity & Resistance Testing

Verified every coil for continuity and measured resistance to ensure balanced windings before final assembly.

14

Squirrel Cage Integration

Installed the custom squirrel cage windings onto the 3D-printed rotor adapter.

5

Stator Core Assembly

Assembled the complete stator core by pressing the individual laminations into a solid, rigid stack.

10

Acrylic Side Panels

Installed transparent acrylic sides to create a fully visible, educational motor housing.

15

Wye-Delta Starter Circuit

Built a Wye-Delta starting circuit on protoboard to safely start the motor at reduced voltage.

downloads

Download Project Resources

downloadbutton.webp

Schematics

(PDF) - 4.8 MB

downloadbutton.webp

BOM + Cost Analysis

(Excel) - 312 KB

downloadbutton.webp

Media & Demo Pack

(Photos + Videos) - 87 MB

downloadbutton.webp

All Files Combined

(Full Archive) - 95 MB

All Code & Designs released under MIT License - For educations & non-commercial use

  • LinkedIn
  • GitHub

EM

bottom of page